Suspensions and methods for deposition of luminescent materials and articles produced thereby

ABSTRACT

The present invention provides suspensions and methods for depositing luminescent materials (e.g., phosphors) using electrophoresis, particularly during the preparation of display devices, such as field emission display devices, and the articles produced thereby. The luminescent material is deposited onto a substrate having thereon a metal-containing transparent, conductive coating. The suspension includes a nonaqueous liquid, a luminescent material, and a salt of a metal of the transparent, conductive coating.

STATEMENT OF GOVERNMENT RIGHTS

This invention was made with U.S. Government grant support underContract No. DABT 63-93-C-0025 awarded by Advanced Research ProjectsAgency. The U.S. Government has certain rights in this invention.

FIELD OF THE INVENTION

The present invention is directed to suspensions of luminescentmaterials (e.g., phosphors) and to methods for depositing layers ofthese materials, particularly during the preparation of display devices,such as field emission display devices, and the articles producedthereby.

BACKGROUND OF THE INVENTION

Display devices, such as desk-top computer screens and direct view andprojection television sets, include electron excited cathodoluminescentdisplay devices such as cathode ray tubes. Cathode ray tubes (CRTs)function as a result of a scanning electron beam from an electron gunimpinging on phosphors on a relatively distant glass screen. Thephosphors absorb the energy from the electron beam and subsequently emita portion of the energy, which is typically in the visible region of theelectromagnetic spectrum. This visible emission is then transmittedthrough the glass screen to the viewer. Other display devices, such asfield emission displays for use in flat panel display screens, whichinclude cold cathode emission devices, and vacuum fluorescent displaysfor use in handheld calculators, which include hot cathode emissiondevices, also function as a result of electrons exciting phosphors on ascreen.

Phosphors are inorganic or organic luminescent materials that mayinclude “activator” atoms that can modify the emitted radiation, suchthat the emission is in the visible region, as well as modify theemission intensity and the persistence of the image. Phosphors shouldpreferably be capable of maintaining luminescence (e.g., fluorescence)under excitation for a relatively long period of time (e.g., about 5milliseconds) to provide superior image reproduction. Also, in general,it is desirable to produce highly pure phosphors to increase absorptionof the available excitation energy by the activator that emits therequired radiation, rather than being consumed by other impurities or“killer” centers, which would result in lower luminescence and lowerefficiency. Therefore, the quality of the deposited phosphor is animportant parameter.

Typically, in field emission displays, powder electroluminescent cells,and other electroluminescent articles, the phosphor is deposited on aninsulating substrate coated with a transparent, conductive material suchas of indium tin oxide (ITO). A method for producing deposits ofphosphors (typically, separate tracks of red, green, and blue phosphors)is electrophoresis (i.e., electrophoretic deposition). Inelectrophoresis, phosphor particles are deposited from a suspensionunder the action of an electric field. The suspension typically includesa nonaqueous liquid, such as an alcohol, and an electrolyte, such as asalt of yttrium, aluminum, lanthanum, or thorium. Such metal salts makeit possible to electrically charge the phosphor particles and serve as abinder making it possible to obtain a highly adhesive coating. The partcoated can serve either as the anode (anaphoresis) or cathode(cataphoresis).

Certain electrophoretic deposition methods result in nonreproducible andinhomogeneous phosphor layers. Others result in the underlying coating(e.g., indium tin oxide) losing its transparency or otherwise beingdeteriorated as by discoloration and reduced conductivity. U.S. Pat. No.5,536,383 (Van Danh et al.) discloses a method that avoids theseproblems; however, this method uses a suspension that includes analiphatic alcohol (except methanol), a powdered luminescent material, ametal salt, as well as other organic materials such as nitromethane anda vegetable protein. The metal salts can be salts of rare earth andalkaline earth metals. They can also be thorium, aluminum and/or cobaltsalts. Preferably, they are hydrated nitrate salts of Mg, La, Al, Th,and Co.

There is a need for other electrophoretic deposition methods that aresimpler and substantially eliminate the deterioration (e.g.,discoloration and reduced conductivity) of the transparent, conductivecoating.

SUMMARY OF THE INVENTION

The present invention provides suspensions and methods for depositingluminescent materials by electrophoresis: Thus, in one embodiment, theinvention is directed to a suspension for the deposition of aluminescent layer onto a substrate having thereon a metal-containingtransparent, conductive coating, the suspension comprising a nonaqueousliquid, a luminescent material, and a salt of a metal of thetransparent, conductive coating.

In another embodiment of the invention, a suspension is provided for thedeposition of a luminescent layer onto a substrate having thereon ametal-containing transparent, conductive coating comprising indium tinoxide, the suspension comprising, a polar organic liquid, a dielectricphosphor, and a salt of a metal of the transparent, conductive coating.

In yet another embodiment of the invention, a method for depositing aluminescent layer on a substrate having thereon a metal-containingtransparent, conductive coating is provided. The method includes:providing a suspension comprising a nonaqueous liquid, a luminescentmaterial, and a salt of a metal of the transparent conductive coating;and depositing (i.e., coating) the suspension onto the substrate to forma layer of luminescent material.

Another method for depositing a luminescent layer on a substrate havingthereon a metal-containing transparent, conductive coating comprisingindium tin oxide is provided. The method includes: providing asuspension comprising, a polar organic liquid, a dielectric phosphor,and a salt of a metal of the transparent, conductive coating; anddepositing the suspension onto the substrate to form a layer ofluminescent material.

The present invention also provides coated substrates and field emissiondisplay devices. In one embodiment, a field emission display devicecomprises a substrate having thereon a metal-containing transparent,conductive coating, and further having deposited thereon a luminescentmaterial, and an oxide of a metal of the transparent, conductivecoating.

In another embodiment, a field emission display device comprises asubstrate having thereon a metal-containing transparent, conductivecoating comprising indium tin oxide, and further having depositedthereon; a dielectric phosphor, and an oxide of a metal of thetransparent, conductive coating.

Also provided is a substrate comprising a metal-containing transparent,conductive coating on at least one surface of the substrate, and a layerof luminescent material deposited on the metal-containing transparent,conductive coating, wherein the layer of luminescent material comprisesan oxide of a metal of the transparent, conductive coating.

In another embodiment, a substrate is provided that comprises ametal-containing transparent, conductive coating on at least one surfaceof the substrate, and a layer of dielectric phosphor deposited on themetal-containing transparent, conductive coating, wherein the layer ofdielectric phosphor comprises an oxide of a metal of the transparent,conductive coating.

Yet another embodiment provides a substrate comprising ametal-containing transparent, conductive coating on at least one surfaceof the substrate, and a layer of luminescent material deposited on themetal-containing transparent, conductive coating, wherein themetal-containing transparent conductive coating comprises indium tinoxide and the layer of luminescent material comprises an oxide of ametal of the transparent, conductive coating.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a cross-sectional schematic of field emission display devicethat includes phosphors made by the method of the present invention.

FIG. 2 is a graph of the luminance of a luminescent material depositedon an indium tin oxide conductive coating with and without an indiumsalt.

DETAILED DESCRIPTION

The present invention provides suspensions and methods for depositingluminescent materials, particularly dielectric phosphors andsemiconductive phosphors, onto a substrate in the preparation of fieldemission displays, powder electroluminescent cells, and the like. Thesuspensions and methods of the present invention are advantageousbecause they reduce or substantially eliminate the deterioration (e.g.,reduced transparency and conductivity) of display devices.

The substrate on which the luminescent material is deposited is atransparent, insulating substrate, having a metal-containingtransparent, conductive coating thereon. A preferred transparent,insulating substrate is glass. The transparent conductive coating is oneof indium tin oxide (ITO), tin oxide, cadmium oxide, zinc oxide, and thelike. Preferably, the transparent conductive coating is indium tin oxideor tin oxide. More preferably, the transparent conductive coating isindium tin oxide.

The method involves the use of a suspension of particles of aluminescent material in a nonaqueous liquid. The luminescent materialcan be a wide variety of materials capable of being produced inparticulate form. Typical luminescent materials are phosphors.Particularly suitable phosphors for use in field emission displays, forexample, are dielectric (nonconducting) phosphors. Examples of suchphosphors include, but are not limited to, manganese- andarsenic-activated zinc silicate (P39 phosphor), titanium-activated zincsilicate (P52 phosphor), manganese-activated zinc silicate (P1phosphor), cerium-activated yttrium silicate (P47 phosphor),manganese-activated magnesium silicate (P13 phosphor), lead- andmanganese-activated calcium silicate (P25 phosphor), terbium-activatedyttrium silicate, terbium-activated yttrium oxide, terbium-activatedyttrium aluminum oxide (P53 phosphor), terbium-activated gadoliniumoxide, terbium-activated yttrium aluminum gallium oxide, and the like.These materials are typically of a particle size of less than about 20microns (μm), but often less than about 10 microns, and preferably, lessthan about 5 microns, although larger sized particles can be producedand milled to a smaller particle size. The luminescent material (ormixture of various luminescent materials) is typically present in thesuspension in an amount of less than about 10 grams/liter, althoughlarger amounts are possible as long as a generally stable dispersion isproduced with little or no sedimentation. Typically, at least about 1gram/liter luminescent material (or mixture of luminescent materials) ispresent in the suspension.

The nonaqueous liquid used to prepare the suspensions of the presentinvention can be a wide variety of liquids commonly used in theelectrophoretic deposition of phosphors. These include, but are notlimited to, polar organic liquids such as alcohols (e.g., methanol,ethanol, isopropanol), ketones (e.g., acetone), and aldehydes (e.g.,acetaldehyde). Trace amounts of water may be present in the organicliquids. Significantly, other organic materials are not needed for thepreparation of field emission display devices to avoid the adverseresults of conventional electrophoresis deposition methods. For example,organic materials such as nitromethane and vegetable proteins are notneeded in the suspensions and methods of the present invention foradvantage to be realized.

The suspension advantageously includes a salt of one or more of themetals of the transparent, conductive coating. For example, if thetransparent, conductive coating is indium tin oxide, the metal salt canbe a salt of indium and/or a salt of tin. If the transparent, conductivecoating is tin oxide, the metal salt can be a salt of tin. If thetransparent, conductive coating is zinc oxide, the metal salt can be asalt of zinc. Such metal salts include counterions that allow for thesalts to be solubilized in polar organic liquids. Typically, andpreferably, the nitrate counterions are used, although othercounterions, such as chloride, may also be used. This metal saltprimarily serves as an electrolyte to increase the conductivity of thesuspension, thereby decreasing the voltage necessary for deposition, andto provide the phosphor with a net positive charge. The metal salt canalso serve as an inorganic binder for improving the adhesion of thedeposited luminescent material to the underlying transparent, conductivecoating.

The use of a salt of one of the metals of the transparent, conductivecoating provides advantage over conventional electrophoretic depositionmethods. It has been discovered that the use of such a metal saltsubstantially eliminates the deterioration (e.g., discoloration andreduced conductivity) of the transparent, conductive coating. This isaccomplished without the need for nitromethane or a vegetable protein,which are undesirable because these can lead to large deposits oforganic materials in an electrophoretically deposited layer. The metalsalt (or mixture of metal salts) is typically present in the suspensionin an amount effective to provide a desirably conductive suspension.Preferably, the metal salt (or mixture of metal salts) is present in thesuspension in an amount of at least about 1×10⁻⁵ mole/liter. Preferably,the metal salt (or mixture of salts) is present in the suspension in anamount of no greater than about 1×10⁻⁴ mole/liter. For introducing themetal salt (or mixture of metal salts) into the nonaqueous liquid (e.g.,polar organic liquid), the metal salt can be initially dissolved in avery small amount of water, although this is not necessarily required,particularly if the metal salt crystal lattice includes molecules ofhydration and/or if the nonaqueous liquid includes a small amount ofwater (such as occurs with isopropanol).

The present invention also provides methods for depositing luminescentlayers, particularly phosphor layers, onto an electrically insulating,transparent substrate having a metal-containing conductive, transparentcoating thereon. The methods of the present invention preferably involvedeposition (i.e., coating) of a luminescent material using standardeletrophoretic techniques, although other techniques can be used. Incataphoresis, for example, the method involves depositing a luminescentmaterial from a suspension of the luminescent material by applying asuitable voltage (typically about 1-40 volts/cm, which may be constantor pulsed) between an anode and a cathode. The coated substrate is usedas the cathode. The anode can be provided by a wide variety ofmaterials, such as platinum or stainless steel, for example. Typically,the luminescent materials are deposited in an amount to produce a layerranging in thickness from about 3 microns to about 5 microns.

The suspensions and methods described herein can be used for depositinga wide variety of luminescent materials in a wide variety of displaydevices. Although the suspensions and methods of the present inventionare particularly suitable for use in the preparation of field emissiondisplays, they can be used to prepare a variety of other electronexcited fluorescent display devices, such as a standard CRT. Thesedisplays can be used for virtual reality screens, book video screens,head-mounted display devices, and the like. Typically, dielectric(nonconductive) phosphors are used on the metal-containing transparent,conductive coating (e.g., ITO) of such devices, instead of conductivephosphors. Although conductive phosphors are more desirable for fieldemission displays because they eliminate charge build-up, dielectricphosphors are normally used due to the limited availability ofconductive phosphors.

An additional and unexpected advantage of the suspensions and methods ofthe present invention is that they produce a conductive oxide on theluminescent material that allows for any excess charge that builds up onthe luminescent material to leak away. For example, if indium tin oxideis the transparent, conductive coating on which the luminescent material(e.g., phosphors) is deposited, and indium nitrate is the salt used inthe suspension to deposit the luminescent material, at least some indiumhydroxide, formed at the cathode during electrophoretic deposition, willdeposit as well. The indium hydroxide is deposited on at least a portionof the particles of the luminescent material, and typically in at leastsome of the voids between the luminescent particles. Indium hydroxideconverts to indium oxide upon thermal treatment. The indium hydroxide istypically heated to over 300° C. to convert it, preferably completely,to indium oxide. For example, it can be heated to 700° C. for 2 hours ina belt furnace. This heating step (i.e., firing) is typically carriedout in air, although subsequently as is typically done, the screens arebaked in a vacuum at about 10% torr and 500° C. for about 10 hours toeliminate volatile impurities. Some reduction of the surface of theoxide is expected to occur during this subsequent step, which willenhance the surface conductivity of the indium oxide.

Thus, at least a portion of the layer of the luminescent materialincludes a metal oxide, which may be coated on the particles and/orbetween the particles. Such metal oxides, such as indium oxide, areconductive, thereby allowing for leakage of excess charge that builds upon the luminescent material (e.g., dielectric phosphors) when it is usedin display devices. This is advantageous because the build up of chargeon the dielectric phosphors leads to negatively charged coatedsubstrates, which repel electrons, hence reducing the light output fromthe dielectric phosphors.

The present invention also provides display devices, particularly fieldemission display devices, that are more efficient at low voltage, highcurrent modes. Field emission displays typically include a display panelhaving a transparent gas-tight envelope, and two main planar electrodesarranged within the gas-tight envelope parallel with each other. One ofthe two main electrodes is a cold cathode with a grid, and the other isan anode. The anode may consist of a transparent glass plate, atransparent electrode formed on the transparent glass plate, and aphosphor layer coated on the transparent electrode. Devices such as thisare further disclosed in U.S. Pat. Nos. 5,210,472, 5,372,973, and5,577,943, for example.

A portion of a field emission display employing a cold cathode is shownin FIG. 1, for example. Referring to this figure, substrate 11 can bemade of glass, for example, or a variety of other suitable materials.Preferably, a single crystal silicon layer serves as substrate 11 ontowhich a conductive material layer 12, such as doped polycrystallinesilicon, has been deposited. At a field emission site location, aconical micro-cathode 13 has been constructed on top of substrate 11.Surrounding the micro-cathode 13, is a low potential anode gatestructure 15. When a voltage differential, through source 20, is appliedbetween the cathode 13 and the gate 15, a stream of electrons 17 isemitted toward anode plate 16. The electron emission tip 13 is integralwith the single crystal semiconductor substrate 11, and serves as acathode conductor. Gate 15 serves as a low potential anode or gridstructure for its respective cathode 13. A dielectric insulating layer14 is deposited on the conductive cathode layer 12, and has an openingat the field emission site location.

Anode plate 16 includes a transparent, electrically conductive coatingdeposited on an insulating transparent substrate, which is positionedfacing gate electrode and parallel thereto. The conductive coating is onthe surface of the substrate directly facing gate electrode. Theconductive coating may be in the form of a continuous layer on thesurface of the substrate. Alternatively, it may be in the form ofparallel and electrically isolated stripes or bands on the surface ofthe substrate. Anode plate 16 also includes a luminescent layerdeposited over the conductive coating so as to be directly facing andimmediately adjacent gate electrode.

Field emission display devices produced by depositing a luminescentlayer which contains the salt of the metal in the conductive coating onan insulating transparent substrate having a conductive coating were twotimes more efficient at light output than standard displays. See, forexample, FIG. 2, which is a graph of the luminance relative tocoloumbs/cm², of a luminescent material deposited an ITO coating on withand without the use of an indium salt (i.e., electrolyte).

The complete disclosure of all patents, patent documents, andpublications cited herein are incorporated by reference. The foregoingdetailed description and example have been given for clarity ofunderstanding only. No unnecessary limitations are to be understoodtherefrom. The invention is not limited to the exact details shown anddescribed, for variations obvious to one skilled in the art will beincluded within the invention defined by the claims.

What is claimed is:
 1. A method of depositing a luminescent layer on afield emission display substrate having thereon a metal-containingtransparent, conductive coating, the method comprising: providing asuspension comprising: a nonaqueous liquid; a luminescent material; anda salt of a metal of the transparent conductive coating, wherein thesalt is present in the suspension at a concentration of no greater thanabout 1×10⁻⁴ mole/liter; and depositing the suspension onto thesubstrate to form a layer of luminescent material and reduce thedeterioration of the transparent conductive coating.
 2. The method ofclaim 1 wherein the luminescent material is a phosphor.
 3. The method ofclaim 1 wherein the metal-containing transparent, conductive coatingcomprises indium tin oxide.
 4. The method of claim 3 wherein the saltcomprises a salt of indium.
 5. The method of claim 4 wherein the indiumsalt is indium nitrate.
 6. The method of claim 1 wherein the nonaqueousliquid is a polar organic liquid.
 7. The method of claim 1 wherein thestep of depositing the suspension comprises depositing the suspension byelectrophoresis.
 8. The method of claim 1 further comprising a step ofheat treating the luminescent layer to form an oxide on at least aportion of the luminescent material.
 9. The method of claim 1 whereinthe salt of a metal of the transparent, conductive coating is selectedto substantially eliminate deterioration of the transparent, conductivecoating.
 10. The method of claim 1 wherein the luminescent materialcomprises luminescent particles and a metal oxide coated on theparticles, between the particles, or both.
 11. A method of reducingdeterioration of a metal-containing transparent, conductive coating in afield emission display, the method comprising: providing a suspensioncomprising: a polar organic liquid; a dielectric phosphor; and a salt ofa metal of the transparent, conductive coating, wherein the salt ispresent in the suspension at a concentration of no greater than about1×10⁻⁴ mole/liter; and depositing the suspension onto the substrate toform a layer of luminescent material on the transparent, conductivecoating.
 12. The method of claim 1 wherein the luminescent materialcomprises dielectric phosphor particles and a metal oxide coated on theparticles, between the particles, or both.
 13. A method of depositing aluminescent layer on a substrate for use in a field emission display,the substrate having thereon a metal-containing transparent, conductivecoating, the method comprising: providing a suspension comprising: anonaqueous liquid; a luminescent material; and a salt of a metal of thetransparent conductive coating, wherein the salt is present in thesuspension at a concentration of no greater than about 1×10⁻⁴mole/liter; and depositing the suspension onto the substrate to form alayer of luminescent material.
 14. The method of claim 13 wherein thesalt of a metal of the transparent, conductive coating is present in thesuspension at a concentration of at least about 1×10⁻⁵ mole/liter. 15.The method of claim 13 wherein the luminescent material comprises adielectric phosphor.
 16. The method of claim 15 wherein the dielectricphosphor comprises particles having a size of less than about 20microns.
 17. The method of claim 15 wherein the dielectric phosphorcomprises particles having a size of less than about 10 microns.
 18. Amethod of depositing a luminescent layer on a field emission displaysubstrate having thereon a metal-containing transparent, conductivecoating, comprising indium tin oxide, the method comprising: providing asuspension comprising: a polar organic liquid; a dielectric phosphor;and a salt of a metal of the transparent, conductive coating, whereinthe salt is present in the suspension at a concentration of no greaterthan about 1×10⁻⁴ mole/liter; and depositing the suspension onto thesubstrate to form a layer of luminescent material.
 19. The method ofclaim 18 wherein the salt of a metal of the transparent, conductivecoating is present in the suspension at a concentration of at leastabout 1×10⁻⁵ mole/liter.
 20. The method of claim 18 wherein thedielectric phosphor comprises particles having a size of less than about20 microns.
 21. The method of claim 18 wherein the dielectric phosphorcomprises particles having a size of less than about 10 microns.
 22. Amethod of depositing a luminescent layer on a substrate for use in afield emission display, the substrate having thereon a metal-containingtransparent, conductive coating, the method comprising: providing asuspension comprising: a nonaqueous liquid; a luminescent material; anda salt of a metal of the transparent conductive coating, wherein thesalt is present in the suspension at a concentration of no greater thanabout 1×10⁻⁴ mole/liter, and wherein the salt provides the luminescentmaterial with a net positive charge; and depositing the suspension ontothe substrate to form a layer of luminescent material.
 23. A method ofdepositing a luminescent layer on a field emission display substratehaving thereon a metal-containing transparent, conductive coating,comprising indium tin oxide, the method comprising: providing asuspension comprising: a polar organic liquid; a dielectric phosphor;and a salt of a metal of the transparent, conductive coating, whereinthe salt is present in the suspension at a concentration of no greaterthan about 1×10⁻⁴ mole/liter, and wherein the salt provides thedielectric phosphor with a net positive charge; and depositing thesuspension onto the substrate to form a layer of luminescent material.